Insert earphone assembly for audiometric testing and method for making same

ABSTRACT

An improved insert earphone for audiometric testing is provided, having a housing, a receiver located within the housing, a flexible eartip located externally to the housing, and a tube nipple acoustically coupled between the receiver and the flexible eartip. The flexible eartip has a flexible tube portion that is coupled to an output end of the tube nipple, which may be rigid. The housing and tube nipple are configured and arranged such that the angle between a longitudinal axis of the tube nipple and the vertical axis is obtuse, minimizing the stress on the ear canal when the flexible eartip is inserted therein. An acoustic damper may be located at or near the input end of the tube nipple to prevent ear wax from clogging the damper and minimize the need for damper replacement.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application makes reference to, and claims priority to, U.S.provisional application Ser. No. 60/156,777 filed Sep. 30, 1999.

INCORPORATION BY REFERENCE

The above-referenced U.S. provisional application Ser. No. 60/156,777 ishereby incorporated by reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

BACKGROUND OF THE INVENTION

Headphone or earphone devices have been used in audiometry applicationsfor some time. One example of such a device that has been used for manyyears is the TDH-39 headphone of Telephonics. The TDH-39 headphonebasically comprises a metal casing that is worn on the head of a user.The casing is fitted with ear cushions that support the headphoneagainst the outer ear in an attempt to attenuate ambient noise levelsduring audiometric testing. While the TDH-39 headphone has been widelyused and accepted in the audiometry industry, it is quite cumbersome anduncomfortable to wear for extended periods of time and the typical leakaround the cushions prevents adequate attentuation of ambient noise. Inaddition, because the TDH-39 has ear cushions that cover the ear canal,the TDH-39 often causes a canal “collapse” problem which may distort auser's hearing and adversely affect audiometric testing results. Whilesuperficial changes have been made to the TDH-39 over the years, suchas, for example, the change from a metal to a plastic cased version(i.e., the TDH-39P), none of these changes have solved the comfort andcanal collapse problems.

Another example of such a device is the ER-3 earphone of EtymoticResearch Inc. The ER-3 device is generally the subject of U.S. Pat. No.4,763,753, and was introduced as an alternative to the TDH-39 foraudiometric testing. The ER-3 comprises a pair of base units that eachhouse a transducer and are each connected to an earpiece via a soundtube. The base units are worn around the neck or shoulder area while theearpieces are inserted into the ear canal of a user. The sound tubes aregenerally long (e.g., 10.95 inches) to enable the positioning of thetransducers a sufficient distance from the ear to minimize anyinterference when the earphones are used, for example, with electricalresponse audiometry as discussed in U.S. Pat. No. 4,763,753.

While the ER-3 provides sufficient ambient noise attenuation, is morecomfortable to wear over extended periods of time, and addresses thecollapsed canal problem, it produces a response that is nearly identicalto that produced by the THD-39 except at 6 and 8 kHz. In addition, someaudiologists have claimed to have difficulty calibrating the ER-3 at 6kHz. At 8 kHz, the response of the ER-3 is attenuated to the point thatit is out of the calibration range of standard audiometers. As can beseen from the frequency response curves set forth in FIG. 1A, the ER-3response also becomes somewhat distorted at higher frequencies (e.g., atgreater than approximately 6–8 kHz).

A further example of a prior art device is the ER-4 earphone of EtymoticResearch Inc. The ER-4 is generally the subject of U.S. Pat. No.5,887,070, and was developed for hi-fidelity music listeningapplications. Because the ER-4 does not have enough output to meet thespecifications of standard audiometers, however, it is generally notsuitable for audiometric testing below approximately 2 kHz.

Further disadvantages and limitations of prior art systems with respectto audiometric testing will become apparent to one of skill in the artthrough comparison of such systems with the present invention as setforth in the remainder of the present application with reference to thedrawings.

SUMMARY OF THE INVENTION

An improved insert earphone for audiometric testing is provided. Theinsert earphone generally includes a housing, a receiver located withinthe housing, a flexible eartip located externally to the housing, and atube nipple. One end of the tube nipple is acoustically coupled to anoutput port of the receiver and the other end of the tube nipple isacoustically coupled to the flexible eartip. In use, a user places theflexible eartip in the user's ear canal such that the housing is locatedproximate the user's ear. Electrical signals received by the receiverfrom an external audio signal source are converted by the receiver intosound. The sound is then transmitted into the ear canal of the user viaa sealed acoustic path including the tube nipple and the flexibleeartip.

In one embodiment, the housing and tube nipple may be configured andarranged such that an angle between a longitudinal axis of the tubenipple and a vertical axis is obtuse, such as 118 degrees, for example.This configuration and arrangement allows the housing to hang proximateto, and comfortably from, the ear while minimizing the stress applied tothe ear canal and/or the eartip.

In another embodiment, the flexible eartip may have a flexible tubeportion and a foam eartip portion. The tube nipple, which may be rigid,is coupled to the flexible tube portion of flexible eartip. The flexibletube portion is of a minimum length such that a user may grasp thehousing and insert the foam eartip portion of the flexible eartip intothe user's ear canal.

In a further embodiment, the tube nipple may have an input end that islocated within the housing and coupled to the receiver, and an outputend located externally to the housing and coupled to the flexibleeartip. The insert earphone may also have an acoustic damper locatedwithin the tube nipple at or near the input end of the tube nipple. Sucha location of the damper away from the output end of the tube nippleeffectively prevents the damper from being clogged with earwax,minimizing the need for damper replacement. Instead, the flexible eartipmay be decoupled from the output end of the tube nipple and replacedwith a new flexible eartip.

Other aspects, advantages and novel features of the present inventionwill become apparent from the following detailed description of theinvention when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates frequency response curves of a prior art earphonedevice.

FIG. 1B illustrates an embodiment of an insert earphone assembly builtin accordance with the present invention.

FIG. 1C illustrates full insertion of an embodiment of an insertearphone assembly built in accordance with the present invention.

FIG. 1D illustrates shallow insertion of an embodiment of an insertearphone assembly built in accordance with the present invention.

FIG. 2 illustrates a desirable configuration of one embodiment of theunitary housing built in accordance with the present invention.

FIG. 3 illustrates detail of one embodiment of the flexible eartip ofFIG. 1.

FIG. 4 illustrates detail of one embodiment of the socket of FIG. 1.

FIG. 5 illustrates one embodiment of the cable of FIG. 1.

FIG. 6 illustrates electrical connections and equalization circuitry forthe embodiment of the cable illustrated in FIG. 5.

FIG. 7 illustrates an alternative embodiment of the tube nipple of FIG.1.

FIG. 8 illustrates the frequency response of the eartip assembly of thepresent invention, as compared to a prior art earphone device.

FIG. 9 illustrates frequency response curves of the insert earphoneassembly of the present invention.

FIG. 10 illustrates the maximum undistorted output of the inventioncompared to that of a prior art device.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1B illustrates an embodiment of an insert earphone assembly 1 builtin accordance with the present invention. The insert earphone 1 has aunitary housing 3. The unitary housing 3 is formed of two housingcomponents 5 and 7 that snap fit against a rigid tube nipple 9 at a topend 11 of the unitary housing 3 and against a socket 13 at a bottom end15 of the unitary housing 3. Alternatively, the housing components 5 and7 may be assembled using screws.

More specifically, housing components 5 and 7 have grooves 17 and 19,respectively, located at the top end 11 of the unitary housing 3 that,upon assembly of the unitary housing 3, engage a flange portion 21 oftube nipple 9. Similarly, housing components 5 and 7 have grooves 23 and25, respectively, located at the bottom end 15 of the unitary housing 3that, upon assembly of the unitary housing 3, engage a flange portion 27of the socket 13. Such a snap fit configuration provides for ease ofassembly and disassembly of the unitary housing 3. Tube nipple 9 may be,for example, an ER 3-04 nipple, and socket 13 may be, for example, anMS868 socket, available from Etymotic Research Inc. Tube nipple 9 mayalso be an integral part of the unitary housing 3. In other words, thetube nipple 9 may be formed as part of the unitary housing 3.

Tube nipple 9 has an outer portion 29 that is located on the outside ofunitary housing 3 and an inner portion 31 that is located within theunitary housing 3. Inner portion 31 of tube nipple 9 mates with aflexible tubing 33 located within the unitary housing 3. Moreparticularly, the inner portion 31 of tube nipple 9 is inserted into anoutput end 34 of a channel in flexible tubing 33. The flexible tubing 33provides an acoustic seal for an input end 37 of the tube nipple 9.

The outer portion 29 of tube nipple 9 likewise mates with a flexibleeartip 39. More particularly, the outer portion 29 of tube nipple 9 isinserted into a tube portion 41 of flexible eartip 39. Tube portion 41forms an acoustic seal between an output end 43 of tube nipple 9 and theear canal of a user. Flexible eartip 39 may be, for example, an ER-14eartip available from Etymotic Research Inc. Other types of eartips mayalso be used, such as, for example, that shown in our U.S. Pat. No.5,887,070.

An acoustic damper 44 is preferably located in inner portion 31 of tubenipple 9, near input end 37 of tube nipple 9. It is desirable to locatethe acoustic damper 44 as such, i.e., far enough away from the outputend 43 of tube nipple 9, so that it does not become clogged from, forexample, ear wax. This wax free and simple construction enables theflexible eartip 39 to be replaced after use, and eliminates the need fora separate damper replacement kit such as that sold with prior artdevices.

Acoustic damper 44 serves to cancel a resonance at lower frequencies.The remaining horn/resonance effect (e.g., between 3 and 5 KHz) is usedto help equalization. Acoustic damper 44 may be, for example, 680 Ω.

A receiver 45 is mounted within unitary housing 3. For example, receiver45 is mounted on an inner surface 47 of housing portion 5. A shockabsorbing material 49 is placed between the surface 47 and the receiver45 to dampen any vibrations that may be transmitted by the unitaryhousing 3. The receiver 45 and shock absorbing material 49 may bemounted using glue or other adhesive type material.

Receiver 45 has an output port 51 that mates with the flexible tubing33. More specifically, output port 51 is inserted into an input end 53of channel 35 in flexible tubing 33. Flexible tubing 33 provides anacoustic seal for the output port 51 of receiver 45.

Receiver 45 is electrically coupled to an audio signal source such as,for example, an audiometer, via wire 55, socket 13 and cable 57. Cable57, may be, for example, an ER5-10 cable available from EtymoticResearch Inc.

During operation of the earphone assembly, electrical signalsrepresentative of sound energy are received from an audio signal source(not shown) and transmitted via cable 57, socket 13 and wire 55 toreceiver 45. Receiver 45 transduces the electrical signals received intosound energy and transmits the sound energy through output port 51. Thesound energy is then coupled to the ear canal of a user through channel35 of flexible tubing 33 and through tube nipple 9. As set forth below,the electrical signals received by the receiver 45 may be equalizedsignals.

FIG. 1C illustrates full insertion of an embodiment of an insertearphone assembly built in accordance with the present invention.Referring to FIG. 1C, there is illustrated the insert earphone assembly1 connected to cable 57 and fully inserted into the ear canal 80 of auser. In accordance with an aspect of the invention, the flexible eartip39 may be fully inserted into the ear canal 80 and the insert earphonemay be supported entirely by the ear canal 80 of the user.

FIG. 1D illustrates shallow insertion of an embodiment of an insertearphone assembly built in accordance with the present invention.Referring to FIG. 1D, there is illustrated the insert earphone assembly1 connected to cable 57 and partially inserted into the ear canal 80 ofa user. In accordance with an aspect of the invention, for shallowinsertion of the earphone 1, the flexible eartip 39 may be partiallyinserted into the ear canal 80. The insert earphone 1, however, maystill be supported entirely by the ear canal 80 of the user.

FIG. 2 illustrates a desirable configuration of one embodiment of theunitary housing 3 built in accordance with the present invention. Angletheta from the vertical axis 58 to a longitudinal axis 60 of the tubenipple 9 is optimized for the typical ear canal, and allows the unitaryhousing 3 to hang vertically along the side of a user's head when worn.Angle theta is an obtuse angle and may be, for example, 118°.

FIG. 3 illustrates detail of one embodiment of the eartip 39 of FIG. 1.As is apparent from FIG. 3, and as mentioned above, flexible eartip 39comprises a tube portion 41 and a foam portion 42. The tube portion 41is flexible and may be PVC-105 tubing. The tube portion 41 extendsthrough foam portion 42 such that sound passes through foam portion 42via tube portion 41, and enters the inner ear when the foam portion 42is fitted within the ear canal of a user. The foam portion 42 generallyprovides an acoustic seal with the ear canal and provides sufficientattenuation of background noise levels for audiometric testing.

As can be seen from FIG. 3, eartip 39 (and thus tube portion 41) mayhave a total length dimension of 26 mm, and the foam portion 42 may havea total length dimension of 13 mm. Because of the short length of thetube portion 41, even though it is flexible, a user may grasp theunitary housing 3 and use the unitary housing 3 as a convenient handlefor inserting the foam portion 42 into the ear canal for sealingtherewith.

FIG. 4 illustrates detail of one embodiment of the socket 13 of FIG. 1.The socket 13 may have the dimensions shown in FIG. 4.

FIG. 5 illustrates one embodiment of the cable 57 of FIG. 1. Cable 57includes a pod 59, button 61, mono plugs 63 and 65, and plugs 67 and 69.Plugs 63 and 65 plug into an audio signal source, such as for example,an audiometer. Plugs 67 and 69 plug into respective earphone assemblies1, one for each ear. Specifically, plug 67 mates with socket 13 ofunitary housing 3 of one earphone assembly 1, and plug 69 mates withsocket 13 of unitary housing 3 of another earphone assembly 1.

FIG. 6 illustrates electrical connections and equalization circuitry forthe embodiment of the cable 57 illustrated in 5. While the equalizationcircuitry is shown as being located in pod 59 of cable 57, it may alsobe located in unitary housing 3 of FIG. 1 or plugs 63 and 65 of cable57.

FIG. 7 illustrates an alternate embodiment of the tube nipple of theeartip assembly of the present invention. Tube nipple 70 may have thedimensions as shown in FIG. 7.

FIG. 8 illustrates the frequency response of the eartip assembly 1 ofFIG. 1. Curve 71 shows the response of the eartip assembly 1 using theequalization circuitry of FIG. 6. For comparison, curve 73 shows theresponse of the prior art eartip mentioned above, i.e., the ER-3A ofEtymotic Research Inc. As can be seen from FIG. 8, the present inventionprovides a better high frequency response than the ER-3A prior arteartip.

FIG. 9 illustrates frequency response curves of the insert earphoneassembly of the present invention. The curves of FIG. 9 are similar tothose mentioned above with respect to FIG. 1A for the prior art ER-3earphone device. As can be seen from a comparison of FIG. 1A and FIG. 9,the present invention provides a better undistorted output at higherfrequencies (i.e., at greater than approximately 6–8 kHz) and a betterhigh frequency response than the prior art ER-3 device. In addition, thepresent invention maintains desired noise isolation and has a lowocclusion effect relative to the prior art.

The present invention therefore solves the collapsed canal problem asachieved by the prior art ER-3, but provides a TDH-39 prior art likeresponse shape at higher frequencies than the ER-3 within thecalibration range of standard audiometers. Just as important, themaximum undistorted output (i.e., having ≦3% THD) at 6 and 8 kHz isapproximately 20–25 dB greater with the present invention than ispossible with the prior art ER-3, as shown in FIG. 10. In other words,the present invention has a response approximately 0 dB relative toTDH-39 and a sensitivity within range of the TDH-39 standard, unlike theER-3. This is achieved by an assembly that is much more compact and ismuch cheaper and easier to manufacture than the prior art ER-3. Inaddition, because of its unique angle (as discussed above with respectto FIG. 2) and its compact design, the assembly of the present inventionis more comfortable to wear than both the prior art TDH-39 and ER-3.

In view of the above-detailed description of the present invention andassociated drawings, other modifications and variations will now becomeapparent to those skilled in the art. It should also be apparent thatsuch modifications and variations may be effected without departing fromthe spirit and scope of the present invention.

1. An insert earphone comprising: a housing; a receiver located in thehousing and having an output port, the receiver for electricallycoupling with an audio signal source; a flexible eartip for acousticsealing with an ear canal of a user; and a tube nipple providing anacoustic pathway through at least one wall of the housing and having afirst end and a second end, the first end being located within thehousing and being acoustically coupled to the output port of thereceiver and the second end being located externally to the housing andbeing acoustically coupled to the flexible eartip, the tube nipple andhousing being configured and arranged to form an obtuse angle between alongitudinal axis of the tube nipple and a vertical axis of the housingwhere the tube nipple meets the housing, wherein the housing hangsapproximately vertically along the side of a user's head when worn; andwherein the insert earphone is inserted at least partially into the earcanal and is supported entirely by the ear canal when worn by the user.2. The insert earphone of claim 1 wherein the angle is approximately 118degrees.
 3. The insert earphone of claim 1 further comprising a flexiblechannel located between the output port of the receiver and the firstend of the tube nipple.
 4. The insert earphone of claim 3 wherein theflexible channel has a first end and a second end, and wherein the firstend of the flexible channel is coupled to output port of the receiverand the second end of the flexible channel is coupled to the first endof the tube nipple.
 5. The insert earphone of claim 1 wherein theflexible eartip comprises a flexible tube portion and a foam eartipportion, and wherein at least a portion of the flexible tube portionextends through the foam eartip portion.
 6. The insert earphone of claim5 wherein the tube nipple is rigid and wherein the second end of thetube nipple is positioned within the flexible tube portion of theflexible eartip.
 7. The insert earphone of claim 1 further comprising anacoustic damper located in the tube nipple proximate the first end ofthe tube nipple.
 8. An insert earphone comprising: a housing; a receiverlocated in the housing and having an output port, the receiver forelectrically coupling with an audio signal source; a flexible eartip foracoustic sealing with an ear canal of a user, the flexible eartip havinga foam eartip portion and a flexible tube portion; a rigid tube nippleproviding an acoustic pathway through at least one wall of the housingand having a first end and a second end, the first end of the rigid tubenipple being located within the housing and being acoustically coupledto the output port of the receiver and the second end of the rigid tubenipple being located externally to the housing and being acousticallycoupled to flexible tube portion of the flexible eartip; and a flexiblechannel located between the output port of the receiver and the firstend of the rigid tube nipple; and wherein the insert earphone isinserted at least partially into the ear canal and is supported entirelyby the ear canal when worn by the user.
 9. The insert earphone of claim8 wherein the flexible channel has a first end and a second end, andwherein the first end of the flexible channel is coupled to the outputport of the receiver and the second end of the flexible channel iscoupled to the first end of the rigid tube nipple.
 10. An insertearphone comprising: a housing; a receiver located in the housing andhaving an output port, the receiver for electrically coupling with anaudio signal source; a flexible eartip for acoustic sealing with an earcanal of a user; and a tube nipple providing an acoustic pathway throughat least one wall of the housing and having a first end and a secondend, the first end being located within the housing and beingacoustically coupled to the output port of the receiver and the secondend being located externally to the housing and being acousticallycoupled to the flexible eartip, the tube nipple and housing beingconfigured and arranged to form an obtuse angle of approximately 118degrees between a longitudinal axis of the tube nipple and a verticalaxis of the housing, wherein the housing hangs approximately verticallyalong the side of a user's head when worn.
 11. The insert earphone ofclaim 10 further comprising a flexible channel located between theoutput port of the receiver and the first end of the tube nipple. 12.The insert earphone of claim 11 wherein the flexible channel has a firstend and a second end, and wherein the first end of the flexible channelis coupled to output port of the receiver and the second end of theflexible channel is coupled to the first end of the tube nipple.
 13. Theinsert earphone of claim 10 wherein the flexible eartip comprises aflexible tube portion and a foam eartip portion, and wherein at least aportion of the flexible tube portion extends through the foam eartipportion.
 14. The insert earphone of claim 13 wherein the tube nipple isrigid and wherein the second end of the tube nipple is positioned withinthe flexible tube portion of the flexible eartip.
 15. The insertearphone of claim 10 further comprising an acoustic damper located inthe tube nipple proximate the first end of the tube nipple.
 16. Aninsert earphone comprising: a housing; a receiver located in the housingand having an output port, the receiver for electrically coupling withan audio signal source; a flexible eartip for acoustic sealing with earcanal of a user; a tube nipple having a first end and a second end, thefirst end located within the housing and acoustically coupled to theoutput port of the receiver and the second end located externally to thehousing and acoustically coupled to the flexible eartip, the tube nippleand the housing being configured and arranged to form an obtuse angle ofapproximately 118 degrees between a longitudinal axis of the tube nippleand a vertical axis of the housing, wherein the housing hangsapproximately vertically along the side of a user's head when worn; andan acoustic damper located in the tube nipple proximate the first end ofthe tube nipple.
 17. The insert earphone of claim 16 wherein theflexible eartip comprises a flexible tube portion and a foam eartipportion, and wherein at least a portion of the flexible tube portionextends through the foam eartip portion.
 18. The insert earphone ofclaim 17 wherein the tube nipple is rigid and wherein the second end ofthe tube nipple is positioned within the flexible tube portion of theflexible eartip.
 19. The insert earphone of claim 16 further comprisinga flexible channel located between the output port of the receiver andthe first end of the tube nipple.
 20. The insert earphone of claim 19wherein the flexible channel has a first end and a second end, andwherein the first end of the flexible channel is coupled to the outputport of the receiver and the second end of the flexible channel iscoupled to the first end of the tube nipple.
 21. An insert earphonecomprising: a housing; a receiver located in the housing and having anoutput port, the receiver for electrically coupling with an audio signalsource; a flexible eartip for acoustic sealing with an ear canal of auser, the flexible eartip having a foam eartip portion and a flexibletube portion; and a tube nipple providing an acoustic pathway through atleast one wall of the housing and having a first end and a second end,the first end of the tube nipple being located within the housing andbeing acoustically coupled to the output port of the receiver and thesecond end of the tube nipple being located externally to the housingand being acoustically coupled to the flexible tube portion of theflexible eartip; the tube nipple and the housing being configured andarranged to form an obtuse angle between a longitudinal axis of the tubenipple and a vertical axis of the housing, wherein the housing hangsapproximately vertically along the side of a user's head when worn;wherein the earphone providing a response that is approximately 0 dBrelative to a response of the TDH-39 standard at at least one of 6 and 8khz, and wherein the second end of the tube nipple is positioned withinthe flexible tube portion of the flexible eartip.
 22. The insertearphone of claim 21, wherein the angle is approximately 118 degrees.23. The insert earphone of claim 21, further comprising a flexiblechannel located between the output port of the receiver and the firstend of the tube nipple.
 24. The insert earphone of claim 23, wherein theflexible channel has a first end and a second end, and wherein the firstend of the flexible channel is coupled to the output port of thereceiver and the second end of the flexible channel is coupled to thefirst end of the tube nipple.
 25. The insert earphone of claim 21,further comprising an acoustic damper located in the tube nippleproximate the first end of the tube nipple.
 26. An insert earphonecomprising: a housing; a receiver located in the housing and having anoutput port, the receiver for electrically coupling with an audio signalsource; a flexible eartip for acoustic sealing with ear canal of a user;a tube nipple having a first end and a second end, the first end locatedwithin the housing and acoustically coupled to the output port of thereceiver and the second end located externally to the housing andacoustically coupled to the flexible eartip; an acoustic damper locatedin the tube nipple proximate the first end of the tube nipple, whereinthe insert earphone is inserted at least partially into the ear canaland is supported entirely by the ear canal when worn by the user, andwherein the tube nipple and the housing being configured and arranged toform an obtuse angle between a longitudinal axis of the tube nipple anda vertical axis of the housing where the tube nipple meets the housing.27. The insert earphone of claim 26, wherein the angle is approximately118 degrees.
 28. The insert earphone of claim 26, wherein the flexibleeartip comprises a flexible tube portion and a foam eartip portion, andwherein at least a portion of the flexible tube portion extends throughthe foam eartip portion.
 29. The insert earphone of claim 28, whereinthe tube nipple is rigid and wherein the second end of the tube nippleis positioned within the flexible tube portion of the flexible eartip.30. The insert earphone of claim 26, further comprising a flexiblechannel located between the output port of the receiver and the firstend of the tube nipple.
 31. The insert earphone of claim 30, wherein theflexible channel has a first end and a second end, and wherein the firstend of the flexible channel is coupled to the output port of thereceiver and the second end of the flexible channel is coupled to thefirst end of the tube nipple.